Paper-based hat and methods for making same

ABSTRACT

Paper-based hats and methods for making same are disclosed. For example, a visor component and a crown component may be obtained from at least one paper-based material, such as a paper-based beverage carton. A crown-visor structure may be formed by affixing at least a portion of a non-exposed surface of the crown component to at least a portion of an upper portion of an exposed surface of the visor component. A band may be affixed to at least a portion of the crown-visor structure to support the paper-based visor on a head of a wearer of the paper-based hat. The visor component and/or the crown component may include images that were printed on the source paper-based material that are visible to an observer of the paper-based hat being worn by a wearer thereof.

BACKGROUND

Traditional source materials for manufacturing apparel include cotton, wool and various polyester-based products. These materials are popular because they are durable, readily formed into patterns for all types of clothing, and are capable of withstanding the stresses imparted by machines used to manufacture garments, such as industrial sewing machines, Serger machines, and presses (for example, for imprinting a pattern or logo). Attempts have been made to use non-traditional materials to produce various types of apparel. For instance, paper and foam materials have been used as a source material for hats. However, conventional hats made from paper and foam are generally either disposable and intended for limited use (for example, paper hats worn by certain restaurant employees) or do not provide the same quality products as traditional materials (for example, sweat absorption and normal use, such as putting on and/or removing the hat, lead to degradation of the hat materials such that the hat becomes useless for the wearer). Accordingly, there is currently not a hat made from non-traditional products, such as paper-based materials, that is attractive, comfortable, and sufficiently durable to withstand normal use by a wearer of the hat.

SUMMARY

The invention described in this document is not limited to the particular systems, methodologies or protocols described, as these may vary. The terminology used herein is for the purpose of describing particular embodiments only, and is not intended to limit the scope of the present disclosure.

It must be noted that as used herein and in the appended claims, the singular forms “a,” “an,” and “the” include plural reference unless the context clearly dictates otherwise. Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of ordinary skill in the art. As used herein, the term “comprising” means “including, but not limited to.”

In an embodiment, a paper-based hat may comprise a visor component and a crown component obtained from at least one paper-based material, at least a portion of a non-exposed surface of the crown component being affixed to at least a portion of an upper portion of an exposed surface of the visor component to form a crown-visor structure; and a band affixed to at least a portion of the crown-visor structure and configured to support the paper-based hat on a head of a wearer of the paper-based hat.

In an embodiment, a paper-based hat may comprise a crown component obtained from a first paper-based material and comprising at least one image element printed thereon and a crown edge lined at least partially lined with a crown edging material; a visor component comprising a second paper-based material and having at least one image element printed thereon, the visor component being configured to have a plurality of incisions in an upper portion thereof and a visor edge lined with a visor edging material, wherein at least a portion of a non-exposed surface of the crown component is affixed to at least a portion of an upper portion of an exposed surface of the visor component to form a crown-visor structure; a head interface structure affixed to a non-exposed surface of at least a portion of the crown-visor structure; and a band affixed to the crown-visor structure and configured to support the paper-based hat on a head of a wearer of the paper-based hat.

In an embodiment, a method of making a paper-based hat may comprise providing at least one paper-based material; obtaining a visor component from the at least one paper-based material; obtaining a crown component from the at least one paper-based material; forming a crown-visor structure by affixing at least a portion of a non-exposed surface of the crown component to at least a portion of an upper portion of an exposed surface of the visor component; and affixing a band to at least a portion of the crown-visor structure to support the paper-based visor on a head of a wearer of the paper-based hat.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts an illustrative paper-based hat according to some embodiments.

FIG. 2A depicts an illustrative paper-based material configured to provide components of a paper-based hat according to some embodiments.

FIG. 2B depicts an illustrative beverage container paper-based material according to some embodiments.

FIG. 3 depicts an illustrative visor component and crown component according to some embodiments.

FIGS. 4A and 4B depict illustrative formation processes for a paper-based hat according to some embodiments.

FIG. 5A depicts an illustrative view of the underside of a paper-product based hat according to an embodiment.

FIG. 5B depicts an illustrative detailed view of the formation of a portion of the paper-based hat according to an embodiment

FIG. 6 depicts an illustrative paper-based hat according to some embodiments.

FIG. 7 depicts a flow diagram for an illustrative method of forming a paper-based hat according to some embodiments.

DETAILED DESCRIPTION

The terminology used in the description is for the purpose of describing the particular versions or embodiments only, and is not intended to limit the scope.

In the following detailed description, reference is made to the accompanying figures, which form a part hereof. In the drawings, similar symbols typically identify similar components, unless context dictates otherwise. The illustrative embodiments described in the detailed description, figures, and claims are not meant to be limiting. Other embodiments may be utilized, and other changes may be made, without departing from the spirit or scope of the subject matter presented herein. It will be readily understood that the aspects of the present disclosure, as generally described herein, and illustrated in the figures, can be arranged, substituted, combined, separated, and designed in a wide variety of different configurations, all of which are explicitly contemplated herein.

The present disclosure is directed toward a paper-based hat constructed at least partially from paper-based materials. The paper-based hat may be configured as a “visor” or “visor style” hat including a visor component and an open crown component generated from paper-based materials. According to some embodiments, the visor component and the crown component may be generated from paper-based materials that include text and/or symbols for various products, companies, sports teams, universities, geographic locations, brands, and the like. In this manner, the paper-based hat may be configured to display the text and/or symbols of paper-based materials from which they were obtained. Accordingly, the paper-based hat may be configured for various purposes including, but not limited to, marketing, advertising, commemorating and/or celebrating an event, demonstrating brand loyalty, and/or providing camaraderie among fellow wearers and/or others having similar interests. In addition, the presence of the text and/or logos may make the paper-based hat appealing to one or more different demographic segments interested in the text and/or logos. For instance, the paper-based materials may include beverage containers, such as paper cartons for cans of beer, having text and symbols associated with the beverage producer. Paper-based hats constructed from such paper-based materials will therefore include the text and symbols from the paper cartons.

FIG. 1 depicts an illustrative paper-based hat according to some embodiments. As shown in FIG. 1, the paper-based hat 100 may include a visor component 105 and a crown component 110. The visor component 105 may be affixed to the crown component 110 and an at least partially elastic strap or band 115 may be affixed to the visor component and/or crown component to support the paper-based hat on the head of a wearer. The band 115 and the structure formed by the visor component 105 and the crown component 110 may form a substantially circular structure generally conforming to the circumference of the head of a wearer. As depicted in FIG. 1, the substantially circular structure may be open such that the top of the head of a wearer remains exposed when wearing the paper-based hat 100, as opposed to the closed crown form associated with a typical baseball hat. The substantially circular structure may be configured to be at least partially smaller than the circumference of the head of a typical wearer such that the strap 115 stretches when the hat 100 is worn, providing a force that operates to maintain the hat on the head of the wearer.

FIG. 2A depicts an illustrative paper-based material configured to provide components of a paper-based hat according to some embodiments. As shown in FIG. 2A, a paper-based material 205 (commonly referred to as a “blank”) may be used as a source of certain components of a paper-based hat. The paper-based material 205 may include various types of paper, including, without limitation, corrugated paper, cardboard, construction paper, paperboard (for example, 3-layer paperboard, 6-layer paperboard, paperboard with fiber and/or plastic reinforcement, and the like), boxboard, chipboard, carrier stock paper, and any other type of paper capable of operating according to some embodiments described herein. In an embodiment, the paper-based material 205 may include paper typically used for beverage containers, such as six (6) pack, twelve (12) pack, eighteen (18) pack, twenty-four (24) pack, or the like beer cartons. In another embodiment, the paper-based material 205 may be associated with one or more coatings, such as wax, glue, plastic, and/or resin-based coatings. In a further embodiment, the paper-based material 205 may include paper material configured from two or more layers of paper-based materials, including two or more layers of the same or different paper-based materials.

One or more components of the paper-based hat may be obtained from the paper-based material 205. For instance, the visor component 210 and/or the crown component 215 may be obtained from the paper-based material 205. In an embodiment, the visor component 210 and/or the crown component 215 may be printed, drawn, scored, perforated or otherwise demarcated on the paper-based material 205 and the visor component and/or the crown component removed from the paper-based material 205. For example, the visor component 210 and/or the crown component 215 may be cut from the paper-based material 205 using a pair of scissors, a saw, or other cutting tool. In an embodiment, one or more dies may be configured in the shape or substantially in the shape of the visor component 210 and/or the crown component 215. The dies may be pressed against the paper-based material 205 with sufficient force to cut out or substantially cut out the visor component 210 and/or the crown component 215, for example, in a manner that does not bend, crease, or otherwise deform the paper-based material. In an embodiment, the dies may be configured to perforate the paper-based material 205 to facilitate removal of the visor component 210 and/or the crown component 215 from the paper-based material. In an embodiment, the dies may be constructed from a rigid material, such as a metal material (for example, steel or steel alloys). In an embodiment, the dies may be pressed against the paper-based material 205 using a press or die cutting machine, such as a mechanical press, a hydraulic press, or the like.

The visor component 210 and/or the crown component 215 may be configured to have certain dimensions 260-275 based on various factors, including the size of the paper-based hat, the head-size of an intended wearer, the size of the paper-based material 205, or the like. In an embodiment, the visor component 210 may have a substantially central width 270 of about 11 inches and a substantially central height 275 of about two (2) and a quarter inches. In an embodiment, the visor component 210 may have a substantially half-circle shape formed similarly or substantially similarly to the visor or bill of a conventional baseball hat. In an embodiment, the crown component 210 may have a substantially central width 265 of about seven (7) inches, a substantially central height 260 of about four (4) and a half inches, and a length from a top peak to the center of the bottom area 280 of about six (6) and a quarter inches. In an embodiment, the crown component 210 may have a substantially elongated shape.

Embodiments are not limited to the particular size and shape of the visor component 210 and/or the crown component 215 described above and/or depicted in FIG. 2A, as these are for illustrative purposes only. Paper-based hats described herein may include components having any dimensions capable of operating according to some embodiments described in this detailed description. In addition, paper-based hats described herein may include components having any shape capable of operating according to some embodiments described in this detailed description.

Although FIG. 2A depicts both the visor component 210 and the crown component 215 being obtained from a single piece of paper-based material 205, embodiments are not so limited. Indeed, the visor component 210 and/or the crown component 215 may be obtained from more than one piece of paper-based material 205. For example, the visor component 210 and the crown component 215 may be obtained from multiple paper-based materials 205 for aesthetic reasons, because different paper-based materials may be more suitable for one component over the other, due to size constraints (for example, the paper-based material is not large enough to supply both components), and/or to obtain different text, symbols, and the like from a source paper-based material.

FIG. 2B depicts an illustrative beverage container paper-based material according to some embodiments. As shown in FIG. 2B, the paper-based material 205 may include a beverage container, such as a paper-based beer carton for holding six (6) pack, twelve (12) pack, eighteen (18) pack, twenty-four (24) pack, or the like cans of beer known to those having ordinary skill in the art. The paper-based material 205 may include various text 220 and/or symbols 225 printed thereon. For instance, the text 220 may include text associated with the producer of the beer and the particular type of beer, while the symbols 225 may include trademarks and images associated with the beer (e.g., images of the beer, beer bottles, beer cans, beer ingredients, or the like), trademarks, and/or other branding symbols. It may be desirable to produce a paper-based hat including such text 220 and/or symbols 225. As such, the visor component 210 and/or the crown component 215 may be obtained from the beverage container paper-based material 205 in a manner that includes at least a portion of the text 220 and/or symbols 225.

According to some embodiments, the visor component 210 and the crown component 215 may be cut from the same or different beverage container paper-based materials 205 such that the text 220 and/or symbols 225 line up on the finished paper-based hat to form a continuous or substantially continuous image. As shown in FIG. 2B, the paper-based material 205 may include various text 220, symbols 225, and/or text and symbol combination 230 a, 230 b. According to some embodiments, the crown component 210 may be configured to include a first portion (for example, a top portion) of text 220, symbols 225, and/or text and symbol combination 230 a, 230 b, while the visor component 215 may be configured to include a second portion (for example, a bottom portion)) of text, symbols, and/or text and symbol combination. For example, in an embodiment, the crown component 210 may include a top portion of a first text and symbol combination 230 a, while the visor component 215 may include a bottom portion of a second text and symbol combination 230 b. A paper-based hat formed from the crown component 210 and the visor component 215 of this embodiment may appear to include one continuous text and symbol combination 230 a, 230 b (see FIG. 6 for a paper-based hat including a substantially continuous text and symbol combination according to some embodiments).

FIG. 3 depicts an illustrative visor component and crown component according to some embodiments. As shown in FIG. 3, a visor component 305 and a crown component 310 may be obtained from one or more paper-based materials. In an embodiment, one or more incisions, cuts, slits, or the like 325 may be made in an upper portion 330 of the crown component 310. The incisions 325 may be made at the time that the crown component 310 is obtained from the paper-based material (for example, a die for removing the crown component from the paper-based material may include components for cutting the incisions) and/or after the crown component has been removed from the paper-based material. The length and number of the incisions 325 may be based on various factors, including, without limitation, the size and/or shape of the crown component 310 and/or the type of paper-based materials. In an embodiment, for a crown component 310 including dimensions similar or substantially similar to the dimensions described in FIG. 2A for visor component 210, crown component 310 may include about nine (9) incisions each having a length of about one (1) to about one (1) and a half inches. However, embodiments are not so limited, as a visor component 310 may include no incisions 325, more or fewer incisions, or incisions having any length capable of operating according to some embodiments provided herein. The incisions 325 may operate, among other things, to prevent creasing, crumpling, wrinkling, or the formation of other unwanted deformations of the crown component 310 during formation of the paper-based hat.

After the visor component 305 and/or the crown component 310 has been removed from the paper-based material, a lining or edging 320 may be provided in whole or in part using various liner materials. The edging 320 may serve, among other things, to strengthen, provide rigidity, and/or to prevent fraying of the visor component 305 and/or the crown component 310. Illustrative edging 320 materials include, without limitation, deformable plastic materials, cotton, polyester materials, and/or any material capable of providing an edging for the visor component 305 and/or the crown component 310 according to embodiments described herein. The edging 320 may be affixed to the visor component 305 and/or the crown component 310 according to various methods, including, but not limited to, the use of staples, the use of glue, and/or sewing.

FIGS. 4A and 4B depict illustrative formation processes for a paper-based hat according to some embodiments. As shown in FIG. 4A, a paper-based hat (for example, paper-based hat 100 depicted in FIG. 1) may include a crown component 410 and a visor component 415. During formation of the paper-based hat, the crown component 410 may be bent at least partially into a curved structure with the ends of the crown component facing away from an exposed surface of the crown component (for example, the exposed surface may be the surface of the crown component that will not be facing the head of the wearer) in the paper-based hat. An upper portion 440 of the visor component 405 may be bent at least partially toward an exposed surface of the visor component (for example, the exposed surface includes the surface of the visor component that will be facing away from the face of the wearer of the paper based hat, for example, a top surface of the visor). As shown in FIG. 4A, bending the visor component 405 may cause the incisions 425 to spread apart to form openings, thereby preventing creasing or other unwanted deformations of the visor component.

At least a portion of the non-exposed side of the crown component 410 may be affixed to at least a portion of the exposed side of the visor component 405 to form a crown-visor structure 445. For example, all, substantially all, or at least a portion of the upper portion 440 of the visor component 405 may be affixed to the crown component 410 using various methods. For instance, the visor component 405 may be affixed to the crown component 410 through the use of glue, the use of tape (for example, double-sided tape), the use of staples, sewing, and/or other methods known to those having ordinary skill in the art.

As shown in FIG. 4B, a head interface component 430 may be configured to provide a contact area between the front of the head of the wearer and the paper-based hat. In this manner, the head of the wearer does not or substantially does not come into contact with the paper-based material used to form the paper-based hat when the wearer is wearing the paper-based hat. Accordingly, sweat, oils, or the like from the skin of the wearer may not come into direct contact with the paper-based material to damage the components of the hat. The head interface component 430 may include a strip of material having a size and shape to cover the crown component 405, the visor component 410, and/or the crown-visor structure 445 over the contact area of the front of the head of the wearer with the paper-based hat. According to some embodiments, the head interface component 430 may include one or more materials capable of absorbing sweat, oils, or the like and/or preventing sweat, oils, or the like from contacting the crown component 405, the visor component 410, and/or the crown-visor structure 445. A non-limiting example of a material for forming the head interface component 430 includes foam, such as polyurethane foam. The head interface component may be affixed to the crown component 405, the visor component 410, and/or the crown-visor structure 445 through various methods, including the use of glue, the use of tape (for example, double-sided tape), the use of staples, sewing, and/or other methods known to those having ordinary skill in the art.

As described above, the paper-based hat may include an at least partially elastic strap or band 435 capable of deforming to the shape or substantially to the shape of at least a portion of the head of a wearer of the paper-based hat. The ends of the band 435 may be affixed to the crown component 405, the visor component 410, the crown-visor structure 445, and/or the head interface component 430 according to various methods. Illustrative and non-restrictive methods include the use of glue, the use of tape (for example, double-sided tape), the use of staples, sewing, and/or other methods known to those having ordinary skill in the art. FIGS. 5A and 5B, described below, depict views of the combination of the crown-visor structure 445, the head interface component 430 and the band 435 depicted in FIG. 4B.

The band 435 is configured to at least partially support the paper-based hat on the head of a wearer. For example, the crown-visor structure 445 and the band 435 may be configured to form a shape that may conform or substantially conform to the shape of the head of the wearer. The length of the band 435 may be configured such that the band may stretch when the wearer puts the paper-based hat on their head. The stretching of the band 435 may provide a force sufficient to hold the hat on the head of the wearer as known to those having ordinary skill in the art.

FIG. 5A depicts an illustrative view of the underside of a paper-product based hat according to an embodiment. The underside view depicted in FIG. 5A illustrates the non-exposed (the bottom) side of the paper-based hat 500 that will face toward the head and/or face of a wearer and away or partially away from an observer of the wearer. The paper-based hat 500 may include a visor component 505, a crown component 510, a band 535, and a head interface component 530. As shown in FIG. 5A, some embodiments provide that the incisions 525 on the crown component 510 may be at least partially exposed (for example, a portion of the bottom of the incision) in the underside of the paper-based hat 500. In such embodiments, the incisions 525 may be obstructed from view on the exposed side of the paper-based hat 500 by the visor component 510.

FIG. 5B depicts an illustrative detailed view of the formation of a portion of the paper-based hat according to an embodiment. The view depicted in FIG. 5B is a detailed view of area 540 of FIG. 5A before the components are affixed to each other. The ends of the band 535 may be arranged within the paper-based hat 500 between the crown component 510 and at least a portion of the head interface component 530. One side of the end portions of the band 535 may be affixed to at least a portion of the crown component 510 and/or the visor component 505 and the head interface component 530 may be layered on top of at least a portion of the end of the band 535. However, embodiments are not limited to the configuration depicted in FIGS. 5A and 5B, as they are provided for illustrative purposes. The visor component 505, crown component 510, head interface component 530, and/or the band component 535 may be arranged according to any configuration capable of operating according to embodiments described herein.

FIG. 6 depicts an illustrative paper-based hat according to some embodiments. As shown in FIG. 6, a paper-based hat 600 may include a visor component 605 and a crown component 610 configured to display an image 650, which may include one or more text and/or symbol elements. For example, for a paper-based hat 600 generated from a beverage container paper-based material, the image 650 may include various elements associated with the beverage, including a name of the beverage producer, a name of the product, trademarks, and/or various images associated with the product, branding, and the like (see FIG. 2B for an illustrative beverage container paper-based material that may be used to generate the paper based hat 600). The image 650 may include a lower portion 655 displayed on the visor component 605 and an upper portion 660 displayed on the crown component 610. According to some embodiments, the visor component 605 and the crown component 610 may be obtained from one or more paper-based materials such that the paper-based hat 600 gives the appearance of a continuous image 650, for instance, as though the visor component and the crown component were formed from one continuous piece having the image displayed thereon.

A paper-product based hat formed according to embodiments described herein is not limited by the paper-product based hats and/or components thereof illustrated in FIGS. 1, 2A, 2B, 3, 4A, 4B, 5A, 5B, and/or 6, as these are provided for illustrative purposes only. Paper-product based hats configured according to embodiments may contain more or fewer components. For example, a paper-product based hat may not include the head interface component. In another example, the paper-product based hat may include additional components as necessary and remain within the scope of this detailed disclosure, such as various functional (for example, structural and/or supportive features) or aesthetic features. In a further example, the components of the paper-based hat (for example, the crown component and/or the visor component) may include various alternative configurations and remain within the scope of this disclosure. For instance, the visor component and/or the crown component may be associated with support and/or reinforcement structures as necessary and/or may be constructed from multiple components (for example, the visor component may be constructed from multiple sections of a paper-based material).

FIG. 7 depicts a flow diagram for an illustrative method of forming a paper-based hat according to some embodiments. At least one paper-based material may be provided 705 for obtaining components for the paper-based hat, such as a paper-based beverage container. In an embodiment, a visor area on the at least one paper-based material for obtaining the visor component may be determined 710 a and a crown area on the at least one paper-based material for obtaining the crown component may be determined such that an image on the at least one paper material will line up on an exposed side of the completed paper-based hat.

In an alternate embodiment, a visor area on the at least one paper-based material may be determined 715 for the visor component and a crown area on the at least one paper-based material may be determined 720 for the crown component. The visor component and the crown component may be removed 725 from the at least one paper-based material. For instance, a die and press may be used to cut the visor component and the crown component from the paper-based material. In an optional step, at least a portion of the edges of the visor component and/or the crown component may be lined 730 a with an edging material.

The visor component may be affixed 735 to the crown component to form a crown-visor structure. A head interface component may be affixed 740 to at least a portion of the crown-visor structure and a headband may be affixed 745 to at least a portion of the crown-visor structure to form the paper-based hat. In an optional step, the paper-based hat may be coated 750 a with one or more coatings, such as a plastic and/or resin coating. The coating may serve to protect certain components of the hat and/or to provide an aesthetic quality to the hat. In an embodiment, the coatings may be transparent, substantially transparent, or semi-transparent such that the images on the components of the paper-based hat remain visible or at least partially visible after the coating or coatings have been applied. In another embodiment, the coatings provide a visible surface of the paper-based hat.

Embodiments are not limited to the steps and/or the order of the steps, including the optional steps, depicted in FIG. 7 as methods for forming a paper-based hat according to embodiments described herein may include more or fewer steps in one or more different sequences.

It will be appreciated that various of the above-disclosed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. It will also be appreciated that various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art which alternatives, variations and improvements are also intended to be encompassed by the following claims. 

What is claimed is:
 1. A paper-based hat comprising: a visor component and a crown component obtained from at least one paper-based material, at least a portion of a non-exposed surface of the crown component being affixed to at least a portion of an upper portion of an exposed surface of the visor component to form a crown-visor structure; and a band affixed to at least a portion of the crown-visor structure and configured to support the paper-based hat on a head of a wearer of the paper-based hat.
 2. The paper-based hat of claim 1, wherein the paper-based material comprises at least one of the following: corrugated paper, cardboard, construction paper, paperboard boxboard, chipboard, carrier stock paper.
 3. The paper-based hat of claim 1, wherein the paper-based material comprises a beverage container.
 4. The paper-based hat of claim 1, wherein at least a portion of a visor edge of the visor component and at least a portion of a crown edge of the crown component are lined with an edging material.
 5. The paper-based hat of claim 1, wherein at least a portion of an upper portion of the visor component comprises a plurality of incisions configured to prevent creasing of the visor component when being affixed to the crown component.
 6. The paper-based hat of claim 1, wherein the visor component comprises a first portion of an image printed thereon and the crown component comprise a second portion of the image printed thereon.
 7. The paper-based hat of claim 6, wherein the visor component and the crown component are obtained from the at least one paper-based material such that the first portion of the image and the second portion of the image line up to form a substantially continuous image on the paper-based hat.
 8. A paper-based hat comprising: a crown component obtained from a first paper-based material and comprising at least one image element printed thereon and a crown edge lined at least partially with a crown edging material; a visor component comprising a second paper-based material and having at least one image element printed thereon, the visor component being configured to have a plurality of incisions in an upper portion thereof and a visor edge lined with a visor edging material, wherein at least a portion of a non-exposed surface of the crown component is affixed to at least a portion of an upper portion of an exposed surface of the visor component to form a crown-visor structure; a head interface structure affixed to a non-exposed surface of at least a portion of the crown-visor structure; and a band affixed to the crown-visor structure and configured to support the paper-based hat on a head of a wearer of the paper-based hat.
 9. The paper-based hat of claim 8, wherein the paper-based material comprises at least one of the following: corrugated paper, cardboard, construction paper, paperboard boxboard, chipboard, carrier stock paper.
 10. The paper-based hat of claim 8, wherein the paper-based material comprises a beverage container.
 11. A method of making a paper-based hat comprising: providing at least one paper-based material; obtaining a visor component from the at least one paper-based material; obtaining a crown component from the at least one paper-based material; forming a crown-visor structure by affixing at least a portion of a non-exposed surface of the crown component to at least a portion of an upper portion of an exposed surface of the visor component; and affixing a band to at least a portion of the crown-visor structure to support the paper-based hat on a head of a wearer of the paper-based hat.
 12. The method of claim 11, wherein the visor component is affixed to the crown component using at least one of the following: glue, staples, tape, and thread.
 13. The method of claim 11, further comprising cutting a plurality of incisions in an upper portion of the visor component configured to prevent creasing of the visor component when affixing the visor component to the crown component.
 14. The method of claim 11, wherein the paper-based material comprises at least one of the following: corrugated paper, cardboard, construction paper, paperboard boxboard, chipboard, carrier stock paper.
 15. The method of claim 11, further comprising lining a visor edge of the visor component and at least a portion of a crown edge of the crown component with an edging material.
 16. The method of claim 11, wherein the paper-based material comprises a beverage container having an image printed thereon.
 17. The method of claim 16, wherein the visor component comprises a first portion of the image printed thereon and the crown component comprise a second portion of the image printed thereon.
 18. The method of claim 17, wherein the first portion of the image and the second portion of the image line up to form a substantially continuous image on the paper-based hat. 